Method and device for manufacturing fiber-reinforced resin material

Abstract

A method for producing a fiber-reinforced resin material in which a bundle of reinforcing fibers (2) is impregnated with a resin material (3), the method comprising: a first step (S11) in which first creases (11a, 11b) extending in the transport direction are formed on a band-shaped material (11) of a first form in which the resin material (3) is impregnated between the reinforcing fibers (2); and a second step (S12) in which the band-shaped material (11) of the first form is pressed from the width direction, the band-shaped material (11) of the first form is folded along the first creases (11a, 11b), and the mutually overlapping surfaces are brought into close contact to form a band-shaped material (12) of a second form.

Description

Technical Field

[0001] The technology disclosed herein belongs to the technical field related to manufacturing methods and apparatus for fiber-reinforced resin materials. Background Technology

[0002] Fiber-reinforced resin materials are used flexibly in various fields as lightweight and high-strength materials. Generally, fiber-reinforced resin materials are manufactured by impregnating a bundle of reinforcing fibers with resin. However, if the resin fails to fill the gaps in the fiber bundle, leaving voids, the material's performance will deteriorate. To reduce such voids, methods using high pressure to impregnate the resin have been used in the past.

[0003] Other manufacturing methods for fiber-reinforced resin materials include, for example, Patent Document 1, which discloses a method in which reinforcing fibers are fed through a powdered thermoplastic resin contained in an impregnation tank, and heated and pressurized using a pair of heated rollers to integrate the resin with the reinforcing fibers. Patent Document 2 discloses a method in which an adhesive is applied to a web of reinforcing fibers, such as textiles, and then the web is cut and the cut web layers are stacked to form a multilayer web. This multilayer web is then clamped into a mold for curing and shaping.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Publication No. 5-57821

[0007] Patent Document 2: Japanese Patent Publication No. 2007-38678 Summary of the Invention

[0008] -The technical problem the invention aims to solve-

[0009] The method of impregnating resin between reinforcing fibers using high pressure to reduce voids suffers from poor manufacturing efficiency. Since the reinforcing fibers and resin in the method of Patent Document 1 are a single layer, it is unsuitable for manufacturing components requiring high strength. The method of Patent Document 2 consists of multiple stages, including cutting, overlapping, and curing of strip materials, resulting in poor manufacturing efficiency and also leading to larger equipment sizes.

[0010] The technology disclosed herein was developed to solve the aforementioned technical problems, and its purpose is to provide a method and apparatus for manufacturing fiber-reinforced resin materials that can efficiently produce high-strength fiber-reinforced resin materials.

[0011] - Technical solutions for solving technical problems -

[0012] To solve the above-mentioned technical problems, the disclosed technology is a method for manufacturing a fiber-reinforced resin material, wherein the fiber-reinforced resin material is formed by impregnating resin material into bundles of reinforcing fibers. The method for manufacturing the fiber-reinforced resin material includes a first step and a second step. In the first step, a first crease extending along the conveying direction is formed on a first-shaped strip material. The first-shaped strip material is formed by impregnating resin material between reinforcing fibers. In the second step, the first-shaped strip material is pressed from the width direction to fold the first-shaped strip material along the first crease, so that the overlapping surfaces are tightly adhered to form a second-shaped strip material.

[0013] Based on the above structure, strip materials can be folded and overlapped through a simple series of processes, thus enabling the formation of high-strength fiber-reinforced resin materials with good manufacturing efficiency.

[0014] In one embodiment, the method for manufacturing the fiber-reinforced resin material may include a preparation step prior to the first step, wherein the resin material is impregnated between reinforcing fibers extending along the conveying direction and arranged in the same direction to form a strip material of the first form.

[0015] Based on the above structure, a series of processes are carried out from forming a strip material in a first form to overlapping the strip material in the first form, thereby enabling the formation of high-strength fiber-reinforced resin materials more efficiently.

[0016] In one embodiment, the manufacturing method of the fiber-reinforced resin material may include a third step and a fourth step. The third step is after the second step. In the third step, a second crease extending along the conveying direction is formed on the second-shaped strip material from a direction different from the direction in which the first crease is formed in the first step. In the fourth step, the second-shaped strip material is pressed from a direction different from the direction in which the pressing is performed in the second step, thereby folding the second-shaped strip material along the second crease, so that the overlapping surfaces are tightly fitted together to obtain the third-shaped strip material.

[0017] Based on the above structure, by overlapping the strip material multiple times from different directions, a higher strength fiber-reinforced resin material can be formed.

[0018] In one embodiment, the process can also be as follows: In the first step, the first crease is formed by rotating the first crease-forming portion of the first crease-forming roller, which is formed circumferentially, while pressing the first strip material of the first shape. The first crease-forming roller has a first axis orthogonal to the conveying direction as its rotation axis. In the second step, the first pressure roller is rotated to press the first strip material of the first shape, causing the first strip material of the first shape to overlap in the direction extending from the first axis, thereby forming the second strip material of the second shape. The first pressure roller has a second axis extending in a direction intersecting the first axis as its rotation axis.

[0019] Based on the above structure, creases are formed and overlapped by using rotating crease-forming rollers and pressure rollers, which makes it easy to continuously perform the first to second processes while conveying the strip material, thus enabling the formation of high-strength fiber-reinforced resin materials more efficiently.

[0020] In one embodiment, the process can also be as follows: In the first step, the first crease is formed by rotating the first crease-forming portion of the first crease-forming roller, which is formed circumferentially, while pressing the strip material of the first shape. The first crease-forming roller rotates about a first axis orthogonal to the conveying direction. In the second step, the first pressure roller rotates and presses the strip material of the first shape, causing the strip material of the first shape to overlap in the direction extending from the first axis, thereby forming the strip material of the second shape. The first pressure roller rotates about a second axis extending in a direction intersecting the first axis. In the third process, the second crease is formed by rotating the second crease-forming part of the second crease-forming roller, which is formed circumferentially, while pressing the second-shaped strip material. The second crease-forming roller has a rotation axis on a third axis extending in a direction intersecting the first axis. In the fourth process, the second pressure roller is rotated to press the second-shaped strip material, causing the second-shaped strip material to further overlap in the direction extending from the third axis, thereby forming the third-shaped strip material. The second pressure roller has a rotation axis on a fourth axis extending in a direction intersecting the third axis.

[0021] Based on the above structure, by using multiple crease-forming rollers and pressure rollers with rotating axes extending in different directions, it is easy to continuously perform the first to fourth processes while conveying the strip material, and to overlap the strip material multiple times from different directions, thereby forming higher strength fiber-reinforced resin materials more efficiently.

[0022] In one embodiment, the crease forming portion may be a concave strip and a convex strip extending along the conveying direction, and a pair of crease forming rollers having the concave strip and the convex strip are clamped into the strip material and rotated while the concave strip and the convex strip engage with each other.

[0023] Based on the above structure, a pair of crease-forming rollers with concave and convex strips can easily form creases on strip materials.

[0024] In one embodiment, the strip material can also be folded along the crease by clamping and pressing the strip material from both sides of the crease using a pair of pressure rollers.

[0025] Based on the above structure, it is easier to overlap strip materials by using a pair of pressure rollers.

[0026] In one embodiment, the crease-forming roller may also be configured such that it alternately has a plurality of the concave strips and a plurality of the convex strips in the direction in which its rotation axis extends, to form a corrugated strip of material with continuous mountain-shaped and valley-shaped creases.

[0027] Based on the above structure, by using multiple concave strips and multiple convex strips to form the strip material into a corrugated shape, multiple layers of the strip material can be overlapped in a single overlapping process, thereby forming a higher strength fiber-reinforced resin material more efficiently.

[0028] Furthermore, the disclosed technology is a manufacturing apparatus for a fiber-reinforced resin material, which is formed by impregnating a bundle of reinforcing fibers with resin material. The manufacturing apparatus comprises a conveying device, a first crease-forming member, and a first pressing member. The conveying device conveys a first-shaped strip material in a conveying direction. The first-shaped strip material is formed by impregnating resin material between reinforcing fibers extending along the conveying direction and arranged in the same direction to form a strip. The first crease-forming member includes a first crease-forming portion extending along the conveying direction. The first crease-forming member presses the first crease-forming portion against the first-shaped strip material. The first pressing member is arranged downstream of the first crease-forming member in the conveying direction. The first pressing member presses the first-shaped strip material from a direction different from the pressing direction of the first crease-forming member, thereby forming a second-shaped strip material in which the first-shaped strip material overlaps in a direction intersecting the conveying direction.

[0029] Based on the above structure, it is possible to fold and overlap strip materials using simple components through a series of processes, thus enabling the formation of high-strength fiber-reinforced resin materials with good manufacturing efficiency.

[0030] In one embodiment, the apparatus for manufacturing the fiber-reinforced resin material may also be configured such that: the second crease-forming member and the second pressure member are arranged downstream of the first pressure member in the conveying direction; the second crease-forming member includes a second crease-forming portion extending along the conveying direction; the second crease-forming member presses the second crease-forming portion toward the second-shaped strip material from a direction different from the pressing direction of the first crease-forming member; the second pressure member is arranged downstream of the second crease-forming member in the conveying direction; and the second pressure member, by pressing the second-shaped strip material from a direction different from the pressing direction of the second crease-forming member, forms a third-shaped strip material by further overlapping the second-shaped strip material in a direction intersecting the conveying direction.

[0031] Based on the above structure, by overlapping the strip material twice from different directions, a higher strength fiber-reinforced resin material can be formed.

[0032] In one embodiment, the first crease forming member may be configured as follows: the first crease forming member is a first crease forming roller with a first axis orthogonal to the conveying direction as its rotation axis; the first crease forming part is a concave strip and a convex strip formed alternately along the circumference of the first crease forming roller and in the direction extending from the first axis; the first crease forming roller forms the first crease on the first-shaped strip material by pressing the concave strip and the convex strip onto the first-shaped strip material and rotating it; the first pressure member is a first pressure roller with a second axis extending in a direction intersecting the first axis as its rotation axis; the first pressure roller folds the first-shaped strip material along the first crease by pressing the first-shaped strip material, so that the overlapping surfaces are tightly fitted together to form a second-shaped strip material.

[0033] Based on the above structure, by using a rotating crease-forming roller and a pressure roller to form creases and overlap them, the first process to the second process can be carried out continuously, thus enabling the formation of high-strength fiber-reinforced resin materials more efficiently.

[0034] In one embodiment, the first crease forming member may be configured as follows: the first crease forming member is a first crease forming roller with a first axis orthogonal to the conveying direction as its rotation axis; the first crease forming portion is formed along the circumference of the first crease forming roller and alternately formed with concave and convex strips in the direction extending from the first axis; the first crease forming roller forms the first crease on the first-shaped strip material by pressing the concave and convex strips onto the first-shaped strip material and rotating it; the first pressure member is a first pressure roller with a second axis extending in a direction intersecting the first axis as its rotation axis; the first pressure roller folds the first-shaped strip material along the first crease by pressing it, so that the overlapping surfaces are tightly fitted together and the first-shaped strip material overlaps in the direction extending from the first axis, thereby forming the second shape. The strip material has a second crease forming component, which is a second crease forming roller with a rotation axis extending along a third axis intersecting the first axis. The second crease forming portion consists of concave and convex strips formed circumferentially along the second crease forming roller and alternately formed in the direction extending along the third axis. The second crease forming roller forms the second crease on the second-shaped strip material by pressing the concave and convex strips onto the second-shaped strip material and rotating it. The second pressure component is a second pressure roller with a rotation axis extending along a fourth axis intersecting the third axis. The second pressure roller folds the second-shaped strip material along the second crease by pressing it, so that the overlapping surfaces are tightly fitted and the second-shaped strip material overlaps in the direction extending along the third axis, thereby forming a third-shaped strip material.

[0035] Based on the above structure, by using multiple crease-forming rollers and pressure rollers with rotating axes extending in different directions, creases can be easily formed and overlapped multiple times continuously, allowing the strip material to be overlapped multiple times from different directions, thereby enabling the formation of higher strength fiber-reinforced resin materials more efficiently.

[0036] -The effects of the invention-

[0037] As explained above, the manufacturing method and apparatus for fiber-reinforced resin materials disclosed herein enable the efficient manufacture of high-strength fiber-reinforced resin materials. Attached Figure Description

[0038] Figure 1 This is a simplified top view of an exemplary apparatus for manufacturing fiber-reinforced resin materials.

[0039] Figure 2 This is a simplified front view of an exemplary apparatus for manufacturing fiber-reinforced resin materials.

[0040] Figure 3 This is a simplified perspective view of an exemplary apparatus for manufacturing fiber-reinforced resin materials.

[0041] Figure 4 It is along Figure 1 The end face view cut along line IV-IV.

[0042] Figure 5 It is along Figure 1 A cross-sectional view taken along the VV line.

[0043] Figure 6 It is along Figure 1 The end face view cut along line VI-VI.

[0044] Figure 7 It is along Figure 1 A cross-sectional view taken along the VV line.

[0045] Figure 8 It is along Figure 1 The end view cut along line VIII-VIII.

[0046] Figure 9 This is a flowchart illustrating an example of a method for manufacturing fiber-reinforced resin materials. Detailed Implementation

[0047] The exemplary embodiments will now be described in detail with reference to the accompanying drawings. In the following description, terms such as left and right, up and down, and front and back are used to indicate direction, but these terms do not limit the arrangement of the constituent elements or the driving direction of the manufacturing apparatus.

[0048] Figure 1 This is a simplified top view of an exemplary manufacturing apparatus 1 for fiber-reinforced resin materials. Figure 2 This is the main view. Figure 3 This is a perspective view. X, Y, and Z in the figure represent the X-axis, Y-axis, and Z-axis directions, respectively. In the following embodiments, the X-axis direction represents the left-right direction, the Y-axis direction represents the front-back direction, and the Z-axis direction represents the up-down direction. These directions can be changed according to the embodiments and are not limited to the driving direction of the manufacturing apparatus. It should be noted that in the following description, upstream side and downstream side refer to the upstream and downstream sides in the conveying direction.

[0049] Manufacturing apparatus 1 is an apparatus for manufacturing fiber-reinforced resin material by impregnating a bundle of resin material 3 into a bundle of reinforcing fibers 2. Manufacturing apparatus 1 is an apparatus for repeatedly folding a strip material formed by impregnating a bundle of resin material 3 into a corrugated shape along a conveying direction. Manufacturing apparatus 1 includes a conveying device (not shown), a first crease forming member 30, a first pressure forming member 40, a second crease forming member 50, and a second pressure forming member 60.

[0050] The reinforcing fiber 2 is not particularly limited, and can be any material that can be used as a fiber-reinforcing resin material, such as carbon fiber, glass fiber, or fibers made from acrylic, bamboo, or hemp. The thickness of the reinforcing fiber 2 is, for example, 1 to 350 μm, preferably 1 to 50 μm. The reinforcing fiber 2 can be of any color. In addition, the reinforcing fiber is only required to be able to be wound, and its hardness is not limited, but for example, a minimum bending radius of 1 mm or more is preferred.

[0051] Resin material 3 is not particularly limited; it can be any material that can be used as a fiber-reinforced resin material, such as either thermosetting resin or thermoplastic resin. It can also use only thermosetting resin, only thermoplastic resin, or both. Colorants and other additives can also be added to the resin material.

[0052] Examples of thermosetting resins include epoxy resins, vinyl ester resins, phenolic resins, acrylate resins, phenoxy resins, polyurethane resins, and cyanate ester resins. One type of thermosetting resin can be used, or two or more thermosetting resins can be used in combination. The viscosity of the thermosetting resin is preferably 100 to 10,000 Pa·sec.

[0053] Examples of thermoplastic resins that can be used include polypropylene, polyamide, polyester resins, styrene resins, fluoropolymers, and olefin resins. One type of thermoplastic resin can be used, or two or more thermoplastic resins can be used in combination. The melt mass flow rate (MFR) of the thermoplastic resin is preferably 5 to 60 g / 10 min.

[0054] The conveying device transports a strip of material in the conveying direction. This strip is formed by impregnating resin material 3 between reinforcing fibers 2 that extend along the conveying direction and are arranged in the same direction. In this embodiment, the conveying direction is the X-axis direction. Figures 1 to 3 In this process, the conveying device continuously transports the strip material from the left side to the right side of the paper. As the conveying device, a general-purpose conveying device that transports the strip or sheet material in a predetermined direction can be used; illustrations are omitted. For example, a winding device arranged at the downstream end of the conveying direction and rotating while winding the strip or sheet material can be used.

[0055] In this embodiment, a fiber unwinding roller 4 and a resin unwinding roller 5 are arranged on the upstream side of the conveying direction. The fiber unwinding roller 4 unwinds the arranged fibers 10 towards the downstream side. The arranged fibers 10 are formed by arranging filamentous reinforcing fibers 2 in the same direction and with a predetermined width. The resin unwinding roller 5 unwinds the resin material 3, which is formed in sheet form and has viscosity, towards the downstream side.

[0056] The fiber unwinding roller 4 and the resin unwinding roller 5 are driven by a conveying device to unwind the arranged fibers 10 and the resin material 3 in the conveying direction. In this embodiment, the fiber unwinding roller 4 unwinds the arranged fibers 10 in a generally horizontal direction, which are formed by arranging a plurality of reinforcing fibers 2 in the Y-axis direction. A guide 20 is provided on the downstream side of the resin unwinding roller 5. The guide 20 guides the resin material 3 so that the resin material 3 is conveyed along the arranged fibers 10 and overlapped on the arranged fibers 10.

[0057] While conveying the aligned fibers 10, the manufacturing apparatus 1 uses a guide 20 to overlap a viscous resin material 3 onto the aligned fibers 10. By overlapping the resin material 3 onto the aligned fibers 10, the reinforcing fibers 2 are impregnated with the resin material 3 to form a strip material. This strip material in this state is referred to as the first-form strip material 11.

[0058] When the resin material 3 is a thermoplastic resin, a heating roller for heating the strip material 11 in the first form can be provided to melt the resin material 3 and keep its viscosity low so that it can penetrate into the spaces between the reinforcing fibers 2 without gaps. Alternatively, when the reinforcing fibers 2 are conductive fibers and the resin material 3 is a thermoplastic resin, by passing an electric current through the reinforcing fibers 2 during transport, the resin material 3 already attached to the reinforcing fibers 2 can be heated and melted, thereby penetrating into the spaces between the reinforcing fibers 2.

[0059] Figure 4 It is along Figure 1 The end view cut along line IV-IV shows a cross-section of the strip material 11 in the first configuration. (See diagram below.) Figure 4 As shown, in the first form of the strip material 11, multiple reinforcing fibers 2 are arranged in a row in the Y-axis direction and become one piece by being impregnated with resin material 3.

[0060] A first crease forming member 30 is arranged on the downstream side of the guide member 20. The first crease forming member 30 is a first crease forming roller with a first shaft 30a orthogonal to the conveying direction as its rotation axis. In this embodiment, the first shaft 30a extends along the Y-axis direction, and a pair of first crease forming rollers 30, 30 with opposite rotation directions are arranged to sandwich the strip material 11 of the first shape in the Z-axis direction.

[0061] The first crease forming roller 30 includes crease forming portions 31 and 32 extending along the conveying direction. The first crease forming roller 30 forms first creases 11a and 11b extending along the conveying direction on the first-shaped strip material 11 by pressing the crease forming portions 31 and 32 toward the first-shaped strip material 11.

[0062] Figure 5 It is along Figure 1 A cross-sectional view taken along the VV line shows a pair of first crease-forming rollers 30, 30, and a strip material 11 with first creases 11a, 11b formed in a first configuration. (See image) Figure 5 As shown, a pair of first crease-forming rollers 30, 30 each include crease-forming portions 31, 32 extending circumferentially along the conveying direction. Specifically, the crease-forming portions 31, 32 are raised ribs 31 and recessed ribs 32. Multiple raised ribs 31 and multiple recessed ribs 32 are alternately formed in the Y-axis direction. In this embodiment, the raised ribs 31 protrude in a direction away from the first axis 30a and are formed circumferentially and over the entire circumference, such as... Figure 5 As shown, when viewed from the conveying direction, the convex strip 31 is a V-shaped and inverted V-shaped protrusion. The concave strip is recessed towards the first axis 30a and is formed circumferentially and over the entire circumference, as shown... Figure 5 As shown, when viewed from the conveying direction, the concave strips are inverted V-shaped and V-shaped grooves. A pair of first crease forming rollers 30, 30 are arranged such that they are spaced apart in a manner that allows the strip material 11 of the first form to pass through, and the convex strips 31 and concave strips 32 of each other engage.

[0063] A pair of first crease forming rollers 30, 30 clamp the first-shaped strip material 11 from the top and bottom, thereby pressing the convex strips 31 and concave strips 32 onto the first-shaped strip material 11. The pair of first crease forming rollers 30, 30 clamp the first-shaped strip material 11 and rotate while engaging the convex strips 31 and concave strips 32, thereby forming mountain-shaped first creases 11a and valley-shaped first creases 11b on the originally planar first-shaped strip material 11. Multiple mountain-shaped first creases 11a and multiple valley-shaped first creases 11b are alternately formed in the Y-axis direction, giving the first-shaped strip material 11 a corrugated shape. Figure 5 In the first form, the strip material 11 is connected as one piece, but the strip material 11 in the first form can also be separated at the first creases 11a and 11b.

[0064] A first pressing member 40 is arranged downstream of the first crease-forming roller 30. The first pressing member 40 presses the first-shaped strip material 11 from a direction different from the pressing direction of the first crease-forming roller 30, thereby forming a second-shaped strip material 12 formed by overlapping the first-shaped strip material 11 in a direction intersecting the conveying direction. The first pressing member 40 is a first pressure roller with a second shaft 40a as its rotation axis, which extends in a direction intersecting the first shaft 30a. The first pressure roller 40 is a cylindrical member. In this embodiment, the second shaft 40a extends in a Z-axis direction orthogonal to the Y-axis direction and the conveying direction, and a pair of first pressure rollers 40, 40 with opposite rotation directions are arranged to sandwich the first-shaped strip material 11 in the Y-axis direction. The pair of first pressure rollers 40, 40 are arranged at intervals such that the second-shaped strip material 12 can pass through.

[0065] A first pressure roller 40 presses a corrugated strip material 11 with first creases 11a and 11b from both sides in the Y-axis direction, where the Y-axis direction is the width direction of the first-shaped strip material 11. By pressing from both sides of the first creases 11a and 11b, the first pressure roller 40 folds the first-shaped strip material 11 along the first creases 11a and 11b, causing the overlapping surfaces to fit tightly together to form a second-shaped strip material 12.

[0066] Figure 6 It is along Figure 1 The end view cut along line VI-VI shows a cross-section of the strip material in the second form. (See diagram below.) Figure 6 As shown, a first-shaped strip material 11 with multiple first folds 11a and 11b in the Y-axis direction is pressed from both sides in the Y-axis direction to form a second-shaped strip material 12 formed by overlapping the first-shaped strip material 11 in the Y-axis direction.

[0067] A second crease forming member 50 is arranged downstream of the first pressure roller 40. The second crease forming member 50 is a second crease forming roller with a third axis 50a as its rotation axis, the third axis 50a extending in a direction intersecting the first axis 30a. In this embodiment, the second crease forming roller 50 includes a third axis 50a extending along the Z-axis direction. A pair of second crease forming rollers 50, 50 with opposite rotation directions are arranged to sandwich the second-shaped strip material 12 in the Y-axis direction.

[0068] The second crease forming roller 50 includes second crease forming portions 51 and 52 extending along the conveying direction. The second crease forming roller 50 presses the second crease forming portions 51 and 52 toward the second-shaped strip material 12 from a direction different from the direction pressed by the first crease forming portions 31 and 32, thereby forming second creases 12a and 12b extending along the conveying direction on the second-shaped strip material 12.

[0069] Figure 7 It is along Figure 1 A cross-sectional view taken along line VII-VII shows a pair of second crease-forming rollers 50, 50, and a strip material 12 in a second form with second creases 12a, 12b formed thereon. Figure 7 As shown, the second crease-forming roller 50 includes crease-forming portions 51 and 52 extending circumferentially along the conveying direction. Specifically, the crease-forming portions 51 and 52 are raised ribs 51 and recessed ribs 52. Multiple raised ribs 51 and multiple recessed ribs 52 are alternately formed in the Z-axis direction. In this embodiment, the raised ribs 51 protrude in a direction away from the third axis 50a and are continuously formed circumferentially, such as... Figure 7 As shown, when viewed from the conveying direction, the convex strip 51 is a V-shaped and inverted V-shaped protrusion. The concave strip 52 is recessed towards the third axis 50a and is formed circumferentially and over the entire circumference, as shown... Figure 7 As shown, when viewed from the conveying direction, the concave strip 52 is an inverted V-shape and a V-shaped groove. A pair of second crease forming rollers 50, 50 are arranged such that they are spaced apart in a manner that allows the strip material 12 of the second form to pass through, and the convex strips 51 and concave strips 52 engage with each other.

[0070] A pair of second crease forming rollers 50, 50 press the convex strips 51 and concave strips 52 toward the second-shaped strip material 12 by clamping it from the front and rear sides. The pair of second crease forming rollers 50 clamp the second-shaped strip material 12 and rotate while engaging the convex strips 51 and concave strips 52, thereby forming mountain-shaped second creases 12a and valley-shaped second creases 12b on the originally planar second-shaped strip material 12. Multiple mountain-shaped second creases 12a and multiple valley-shaped second creases 12b are alternately formed in the Z-axis direction, giving the second-shaped strip material 12 a corrugated appearance.

[0071] A second pressing member 60 is arranged downstream of the second crease-forming roller 50. The second pressing member 60 presses the second-shaped strip material 12 from a direction different from the pressing direction of the second crease-forming roller 50, thereby forming a third-shaped strip material 13 formed by overlapping the second-shaped strip material 12 in a direction intersecting the conveying direction. The second pressing member 60 is a second pressure roller with a fourth axis 60a as its rotation axis, which extends in a direction intersecting the third axis 50a. The second pressure roller 60 is a cylindrical component. In this embodiment, the fourth axis 60a extends in a Y-axis direction orthogonal to both the Z-axis and the conveying direction. A pair of second pressure rollers 60, 60 with opposite rotation directions are arranged along the Z-axis direction, sandwiching the second-shaped strip material 12. The pair of second pressure rollers 60, 60 are arranged spaced apart in a manner that allows the second-shaped strip material 12 to pass through.

[0072] The second pressure roller 60 presses the second-shaped strip material 12, which has second creases 12a and 12b, from both sides in the Z-axis direction, forming a corrugated second-shape strip material 12. The Z-axis direction is the width direction of the second-shape strip material 12. By pressing the second-shape strip material 12 from both sides of the second creases 12a and 12b, the second pressure roller 60 folds the second-shape strip material 12 along the second creases 12a and 12b, so that the overlapping surfaces are tightly adhered to form a third-shape strip material 13.

[0073] Figure 8 It is along Figure 1 The end face view cut along line VIII-VIII shows a cross-section of the strip material in the third form. (See diagram below.) Figure 8 As shown, a second-shaped strip material 12 with multiple second folds 12a and 12b in the Z-axis direction is pressed from both sides in the Z-axis direction to form a third-shaped strip material 13 that is further overlapped in the Z-axis direction.

[0074] A winding device (not shown) is arranged downstream of the second pressure roller 60. The winding device winds up the strip material 13 in the third form while rotating.

[0075] In this embodiment, after the reinforcing fiber 2 is unwound from the fiber unwinding roller 4 into an array of fibers 10, the array of fibers 10 is processed into a first-form strip material 11, a second-form strip material 12, and a third-form strip material in sequence during the process of being overlapped multiple times, until it is wound up by the winding device. The entire process can be carried out continuously without cutting.

[0076] In this embodiment, a pair of crease-forming rollers 30, 30, 50, 50 are configured to hold the strip material on both sides and rotate respectively, but the configuration is not limited to this. The crease-forming rollers do not necessarily have to be a pair; there can be only one, as long as they can press the crease-forming component against the strip material to form a crease. In this embodiment, a pair of pressure rollers 40, 40, 60, 60 are configured to hold the strip material on both sides and rotate respectively, but the pressure rollers do not necessarily have to be a pair; there can be only one, as long as they can press the strip material. Furthermore, in this embodiment, the configuration involves overlapping the strip material twice in different directions using the first crease-forming component 30, the first pressure component 40, the second crease-forming component 50, and the second pressure component 60, but the number of crease-forming components and pressure components is not limited. It may include one crease-forming component and one pressure component to overlap the strip material only once, or it may include three or more crease-forming components and three or more pressure components to overlap the strip material three or more times.

[0077] Figure 9 This is a flowchart illustrating a method for manufacturing fiber-reinforced resin materials using the manufacturing apparatus 1 of this disclosure. The method for manufacturing fiber-reinforced resin materials of this disclosure includes a preparation step S10, a first step S11, a second step S12, a third step S13, and a fourth step S14.

[0078] Preparation step S10 is a step of impregnating resin material 3 between reinforcing fibers 2 that extend along the conveying direction and are arranged in the same direction to form a first-form strip material 11.

[0079] The first process S11 is a process of forming first creases 11a and 11b extending along the conveying direction on the first-shaped strip material 11. In the first process S11, the first crease forming roller 30 rotates with the first shaft 30a as the rotation axis, pressing the first crease forming portions 31 and 32 formed along the circumferential direction onto the first-shaped strip material 11.

[0080] In the second process S12, the first-shaped strip material 11 is pressed along its width direction to fold it along the first creases 11a and 11b, causing the overlapping surfaces to fit tightly together to form the second-shaped strip material 12. In the second process S12, the first pressure roller 40 rotates around the second axis 40a to press the first-shaped strip material 11, causing the first-shaped strip material 11 to overlap in the direction extending from the first axis 30a, thereby forming the second-shaped strip material 12.

[0081] In the third process S13, second creases 12a and 12b extending along the conveying direction are formed on the second-shaped strip material 12 from directions different from those in the first process S11 where the first creases 11a and 11b are formed. In the third process S13, the second crease forming roller 50, with the third axis 50a as its rotation axis, presses the circumferentially formed crease forming portions 51 and 52 onto the second-shaped strip material 12 while rotating, thereby forming the second creases 12a and 12b.

[0082] In the fourth step S14, the second-shaped strip material 12 is pressed from a direction different from that of the second step S12, thereby folding the second-shaped strip material 12 along the second creases 12a and 12b, so that the overlapping surfaces are tightly fitted together to obtain the third-shaped strip material 13. In the fourth step, the second pressure roller 60, with the fourth axis 60a as its rotation axis, rotates and presses the second-shaped strip material 12, causing the second-shaped strip material 12 to further overlap in the direction extending from the third axis 50a, thereby forming the third-shaped strip material 13.

[0083] According to the manufacturing method and apparatus for the fiber-reinforced resin material configured as described above, a high-strength fiber-reinforced resin material can be formed with good manufacturing efficiency by folding and overlapping strip materials through a simple series of processes and repeating these processes multiple times. Furthermore, since the reinforcing fibers can be overlapped multiple times without cutting them, when reusing the fiber-reinforced resin material manufactured by this method and apparatus, the reinforcing fibers can be easily unwound by melting the resin material, allowing for the recovery of longer reinforcing fibers; therefore, its reusability is very high.

[0084] The above embodiments are merely examples and should not be construed as limiting the scope of this disclosure. The scope of this disclosure is defined by the scope of the claims, and any modifications or alterations falling within the equivalent scope of the claims are included within the scope of this disclosure.

[0085] -Industry Applicability-

[0086] The technology disclosed herein is suitable for manufacturing methods and apparatus for fiber-reinforced resin materials.

[0087] - Symbol Explanation -

[0088] 1 Manufacturing apparatus

[0089] 2. Reinforcing Fibers

[0090] 3. Resin materials

[0091] 4 Fiber unwinding roller

[0092] 5 Resin Unwinding Rollers

[0093] 10 Arranged fibers

[0094] 11. First-form strip material

[0095] 11a, 11b First crease

[0096] 12. Second form of strip material

[0097] 12a, 12b Second crease

[0098] 13. Third-form ribbon material

[0099] 20. Guide components

[0100] 30 First crease forming roller (first crease forming component)

[0101] 30a First Axis

[0102] 31. Raised strip (first crease forming part)

[0103] 32. Indentation (first crease forming part)

[0104] 40 First pressure roller (first pressure application component)

[0105] 40a Second Axis

[0106] 50 Second crease forming roller (second crease forming component)

[0107] 50a Third Axis

[0108] 51. Raised strip (second crease forming part)

[0109] 52. Indentation (second crease forming area)

[0110] 60 Second pressure roller (second pressure application component)

[0111] 60a Fourth Axis

[0112] S10 Preparation Process

[0113] S11 First Process

[0114] S12 Second Process

[0115] S13 Third Process

[0116] S14 Fourth Process

Claims

1. A method for manufacturing a fiber-reinforced resin material, wherein the fiber-reinforced resin material is formed by impregnating a resin material into a bundle of reinforcing fibers, characterized in that: The manufacturing method of the fiber-reinforced resin material includes a first step and a second step. In the first step, a first crease extending along the conveying direction is formed on a first-shaped strip material, which is formed by impregnating resin material between reinforcing fibers. In the second step, the first-shaped strip material is pressed along the width direction of the first-shaped strip material to fold the first-shaped strip material along the first crease, so that the overlapping surfaces are tightly attached to form the second-shaped strip material.

2. The method for manufacturing the fiber-reinforced resin material according to claim 1, characterized in that: The method for manufacturing the fiber-reinforced resin material includes a preparation step prior to the first step, wherein the preparation step involves impregnating the resin material between reinforcing fibers that extend along the conveying direction and are arranged in the same direction to form a strip material of the first form.

3. The method for manufacturing the fiber-reinforced resin material according to claim 2, characterized in that: The method for manufacturing the fiber-reinforced resin material includes a third step and a fourth step. The third step is performed after the second step. In the third step, a second crease extending along the conveying direction is formed on the strip material of the second shape from a direction different from the direction in which the first crease is formed in the first step. In the fourth step, the second-shaped strip material is pressed from a direction different from the direction of pressing in the second step, and the second-shaped strip material is folded along the second crease, so that the overlapping surfaces are tightly fitted together to obtain the third-shaped strip material.

4. The method for manufacturing the fiber-reinforced resin material according to claim 2, characterized in that: In the first step, the first crease is formed by pressing the first crease-forming portion of the first crease-forming roller, which is formed circumferentially, against the strip material of the first shape while rotating. The first crease-forming roller rotates about a first axis orthogonal to the conveying direction. In the second process, the first pressure roller is rotated to press the first-shaped strip material, causing the first-shaped strip material to overlap in the direction extending from the first axis, thereby forming the second-shaped strip material. The first pressure roller has a rotation axis with a second axis extending in a direction intersecting the first axis.

5. The method for manufacturing the fiber-reinforced resin material according to claim 3, characterized in that: In the first step, the first crease is formed by pressing the first crease-forming portion of the first crease-forming roller, which is formed circumferentially, against the strip material of the first shape while rotating. The first crease-forming roller rotates about a first axis orthogonal to the conveying direction. In the second process, the first pressure roller is rotated to press the strip material of the first shape, causing the strip material of the first shape to overlap in the direction extending from the first axis, thereby forming the strip material of the second shape. The first pressure roller rotates about a second axis extending in a direction intersecting the first axis. In the third step, the second crease is formed by rotating the second crease-forming portion of the second crease-forming roller, which is formed circumferentially, while pressing the strip material of the second shape. The second crease-forming roller rotates about a third axis extending in a direction intersecting the first axis. In the fourth step, the second pressure roller is rotated to press the second-shaped strip material, causing the second-shaped strip material to overlap further in the direction extending from the third axis, thereby forming the third-shaped strip material. The second pressure roller has a rotation axis with a fourth axis extending in a direction intersecting the third axis.

6. The method for manufacturing the fiber-reinforced resin material according to claim 4 or 5, characterized in that: The crease forming section consists of concave and convex strips extending along the conveying direction. A pair of crease forming rollers having the concave and convex strips are clamped into the strip material and rotate while engaging the concave and convex strips with each other.

7. The method for manufacturing the fiber-reinforced resin material according to claim 6, characterized in that: The strip material is folded along the crease by clamping and pressing it from both sides of the crease using a pair of pressure rollers.

8. The method for manufacturing the fiber-reinforced resin material according to claim 7, characterized in that: The crease-forming roller has alternating concave strips and convex strips in the direction extending along its rotation axis to form a corrugated strip of material with continuous mountain-shaped and valley-shaped creases.

9. An apparatus for manufacturing a fiber-reinforced resin material, wherein the fiber-reinforced resin material is formed by impregnating a bundle of reinforcing fibers with a resin material, characterized in that: The apparatus for manufacturing the fiber-reinforced resin material includes a conveying device, a first crease-forming component, and a first pressurizing component. The conveying device transports the first-shaped strip material in the conveying direction. The first-shaped strip material is formed by impregnating resin material between reinforcing fibers that extend along the conveying direction and are arranged in the same direction, thus forming a strip. The first crease-forming component includes a first crease-forming portion extending along the conveying direction, and the first crease-forming component presses the first crease-forming portion toward the strip material of the first shape. The first pressurizing member is arranged downstream of the first crease forming member in the conveying direction. The first pressurizing member presses the first-shaped strip material from a direction different from the pressing direction of the first crease forming member, thereby forming a second-shaped strip material in which the first-shaped strip material overlaps in a direction intersecting the conveying direction.

10. The apparatus for manufacturing fiber-reinforced resin materials according to claim 9, characterized in that: The apparatus for manufacturing the fiber-reinforced resin material includes a second crease-forming component and a second pressure-applying component. The second crease-forming component is arranged downstream of the first pressing component in the conveying direction. The second crease-forming component includes a second crease-forming portion extending along the conveying direction. The second crease-forming component presses the second crease-forming portion toward the strip material of the second shape from a direction different from the pressing direction of the first crease-forming component. The second pressurizing member is arranged downstream of the second crease forming member in the conveying direction. The second pressurizing member presses the second-shaped strip material from a direction different from the direction pressed by the second crease forming member, thereby forming a third-shaped strip material that is further overlapped in a direction intersecting the conveying direction.

11. The apparatus for manufacturing fiber-reinforced resin materials according to claim 9, characterized in that: The first crease-forming component is a first crease-forming roller that rotates along a first axis orthogonal to the conveying direction. The first crease forming portion is formed along the circumference of the first crease forming roller and consists of alternating concave and convex strips in the direction extending from the first shaft. The first crease-forming roller forms the first crease on the first-shaped strip material by pressing the concave and convex strips onto the first-shaped strip material and rotating it. The first pressure component is a first pressure roller that rotates along a second axis extending in a direction intersecting the first axis. The first pressure roller folds the first-shaped strip material along the first crease by pressing it, so that the overlapping surfaces fit together tightly to form the second-shaped strip material.

12. The apparatus for manufacturing fiber-reinforced resin materials according to claim 10, characterized in that: The first crease-forming component is a first crease-forming roller that rotates along a first axis orthogonal to the conveying direction. The first crease forming portion is formed along the circumference of the first crease forming roller and consists of alternating concave and convex strips in the direction extending from the first shaft. The first crease-forming roller forms the first crease on the first-shaped strip material by pressing the concave and convex strips onto the first-shaped strip material and rotating it. The first pressure component is a first pressure roller that rotates along a second axis extending in a direction intersecting the first axis. The first pressure roller folds the first-shaped strip material along the first crease by pressing it, so that the overlapping surfaces are tightly pressed together and the first-shaped strip material overlaps in the direction extending from the first axis, thereby forming the second-shaped strip material. The second crease forming component is a second crease forming roller that rotates along a third axis extending in a direction intersecting the first axis. The second crease forming portion is formed along the circumference of the second crease forming roller and consists of alternating concave and convex strips in the direction extending from the third axis. The second crease-forming roller forms the second crease on the second-shaped strip material by pressing the concave and convex strips onto the second-shaped strip material and rotating it. The second pressure component is a second pressure roller that rotates along a fourth axis extending in a direction intersecting the third axis. The second pressure roller folds the second-shaped strip material along the second crease by pressing it, so that the overlapping surfaces fit together tightly and the second-shaped strip material overlaps in the direction in which the third axis extends, thereby forming a third-shaped strip material.

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